Three-dimensional (3D) printing of electro-active lenses

Abstract

A method of manufacturing an optic includes disposing electronic circuitry on a substrate. The method also includes depositing a first resin on the first side of the electronic circuitry and curing the first resin to form a first optical segment. The method further includes depositing a second resin on the second side of the electronic circuitry and curing the second resin to form a second optical segment. The first and second optical segments encapsulate the electronic circuitry. The first resin and the second resin can include multiple droplets of resin, thereby reducing mechanical force imposed on the electronic circuitry during printing and allowing conformal contact between the resin and the electronic circuitry. Accordingly, electronic circuitry of smaller dimension can be used to form the electronic eyewear.

The invention claimed is: 
     
         1 . A method of making electronic eyewear, the method comprising:
 arranging a power supply and an electronic module in a temple printing area;   arranging at least two electrical connectors in a frame front printing area;   depositing droplets of lens frame material in the temple printing area and in the frame front printing area;   curing the droplets of lens frame material to form a temple with the power supply and the electronic module embedded therein and to form a frame front with the at least two electrical connectors embedded therein;   forming an optic by additively printing optic material around electronic circuitry in or on a first optical segment having a curved outer surface, the electronic circuitry having conductive components to electrically couple with the at least two electrical connectors;   mechanically coupling the optic to the frame front so that the conductive components in the optic are in electrical contact with the at least two electrical connectors; and   mechanically coupling the frame front to the temple so that the at least two electrical connectors are in electrical contact with the power supply and the electronic module, wherein forming the optic comprises:   depositing a first layer of droplets of optic material on a first side of the electronic circuitry;   curing the first layer of droplets of optic material to form the first optical segment;   flipping over the first optical segment to expose a second side of the electronic circuitry;   depositing a second layer of droplets of optic material on the second side of the electronic circuitry; and   curing the second layer of droplets of optic material to form a second optical segment, the first optical segment and the second optical segment encapsulating the electronic circuitry.   
     
     
         2 . The method of  claim 1 , wherein forming the optic comprises:
 after depositing the first layer of droplets of optic material on the first side of the electronic circuitry, disposing a first electrode on the first side of the electronic circuitry; and   after depositing the second layer of droplets of optic material on the second side of the electronic circuitry, disposing a second electrode on the second side of the electronic circuitry.   
     
     
         3 . The method of  claim 2 , further comprising:
 printing at least one interconnect comprising conductive resin on the electronic circuitry to electrically couple the electronic circuitry to the second electrode on the second side of the electronic circuitry.   
     
     
         4 . The method of  claim 1 , wherein forming the optic comprises forming at least a portion of at least one of a refractive lens or a Fresnel lens. 
     
     
         5 . The method of  claim 1 , wherein the electronic circuitry comprises an electro-active element configured to provide at least one of a variable optical power or a variable tint. 
     
     
         6 . A method of making electronic eyewear,
 arranging a power supply and an electronic module in a temple printing area;   arranging at least two electrical connectors in a frame front printing area;   depositing droplets of lens frame material in the temple printing area and in the frame front printing area;   curing the droplets of lens frame material to form a temple with the power supply and the electronic module embedded therein and to form a frame front with the at least two electrical connectors embedded therein;   forming an optic by additively printing optic material around electronic circuitry in or on a first optical segment having a curved outer surface, the electronic circuitry having conductive components to electrically couple with the at least two electrical connectors;   mechanically coupling the optic to the frame front so that the conductive components in the optic are in electrical contact with the at least two electrical connectors; and   mechanically coupling the frame front to the temple so that the at least two electrical connectors are in electrical contact with the power supply and the electronic module, wherein forming the optic comprises:   forming the first optical segment by depositing optic material in a depression or dimple in a substrate so as to form the curved outer surface facing down;   curing the optic material to form a receptacle or planar surface facing up; and   disposing the electronic circuitry on the receptacle or planar surface.   
     
     
         7 . The method of  claim 1 , wherein the curved outer surface is convex. 
     
     
         8 . The method of  claim 1 , wherein the curved outer surface is concave. 
     
     
         9 . The method of  claim 1 , wherein the curved outer surface is a first curved outer surface having a first non-zero radius of curvature and wherein additively printing the optic material around the electronic circuitry comprises forming a second curved outer surface having a second non-zero radius of curvature different than the first non-zero radius of curvature. 
     
     
         10 . The method of  claim 9 , wherein one of the first curved outer surface or the second curved outer surface is concave and the other of the first curved outer surface or second curved outer surface is convex. 
     
     
         11 . The method of  claim 1 , wherein forming the optic comprises:
 disposing a protective layer on the electronic circuitry before additively printing the optic material around the electronic circuitry.   
     
     
         12 . The method of  claim 1 , wherein the electronic circuitry is first electronic circuitry and forming the optic further comprises:
 disposing second electronic circuitry on the optic material additively printed around the first electronic circuitry; and   additively printing additional optic material around the second electronic circuitry.   
     
     
         13 . The method of  claim 6 , wherein the curved outer surface is convex. 
     
     
         14 . The method of  claim 6 , wherein the curved outer surface is concave. 
     
     
         15 . The method of  claim 6 , wherein the curved outer surface is a first curved outer surface having a first non-zero radius of curvature and wherein additively printing the optic material around the electronic circuitry comprises forming a second curved outer surface having a second non-zero radius of curvature different than the first non-zero radius of curvature. 
     
     
         16 . The method of  claim 15 , wherein one of the first curved outer surface or the second curved outer surface is concave and the other of the first curved outer surface or second curved outer surface is convex. 
     
     
         17 . The method of  claim 6 , wherein forming the optic comprises:
 disposing a protective layer on the electronic circuitry before additively printing the optic material around the electronic circuitry.